Friction Stir Welding ENHANCEMENT SEMINAR Friction Stir Welding

CONTENTS
Introduction to Friction Stir Welding and Processing

Literature Review
Process Variables
Tool geometry
Material flow in FSW
Weld micro structure and mechanical property
Dissimilar FSW
Defects in FSW
Multi pass FSW
Objectives
Experimental work
Results and discussion
Conclusions
Future work
References
INTRODUCTION
Friction stir welding (FSW) is a solid state joining
process.
Invented at The Welding Institute (TWI) of
Cambridge, UK in 1991.
Utilizes a non consumable rotating tool consisting of
a concentric threaded tool pin and tool shoulder.
Transforms the metal from a solid state into a
Plastic like state and the mechanically stir the
materials together under pressure to form a welded
joint.

Fig. 1: Schematic representation of FSW [4]
SEQUENCE OF OPERATION
APPLICATIONS
Aerospace
Ship building
Railway industries
Automobiles
Some of the parts are-
Fuel tank for space launch vehicles
Roofing for railway carriages.
Bodies and floors for coaches, buses.
Wings and fuselage panels of aircraft.
Wheel assemblies.
Connectors.

https://www.apple.com/in/imac/design/
ADVANTAGES OF FSW OVER
OTHER WELDING PROCESS
Retain near-parent material properties across the
weld.
Join similar and dissimilar material, difficult by
conventional processes.
Weld quality is excellent (no porosity).
No melting of material.
Low residual stresses.
No fumes, no filler material, no shielding gases.
Easily automated on simple milling machine-low
setup cost and less training.

FRICTION STIR PROCESSING
LITERATURE REVIEW
Table 1: PROCESS VARIABLES IN FSW
Machine variable

Tool variable

Other variable

Welding speed
Spindle speed
Plunge force
Tool tilt angle

Tool material
Pin and shoulder diameter
Pin length
Thread pitch
Shoulder and tool feat
Joint design
Material Type and size
Property of work piece
material
Type of fixture material

Author Year Findings
Sato et al. 2002 Significant rise of temperature with rise of rotational
speed.
Peel et al. 2006 Both torque and extent of material mixing in the SZ
zone displays a much stronger dependence on the
rotational speed than the traverse speed.
Meran et al. 2006 With const.rpm and varying welding speed finding out
the optimum parameter for defect-free joint
Kwon et al. 2009 Onion ring structure becomes wider as rpm increased.
but grain size decreased with increase in rpm.
Rodrigues et al. 2009 Hot welds obtained with maximum rpm and minimum
traverse speed have improved mechanical properties
relative to cold weld.
Contd.

Raja manickram et
al.
2008 Temperature under the tool was strongly dependent on
the tool rotation rate than the welding speed.
Azizieh et al. 2011 With high rpm, higher heat input occur and
simultaneously more shattering effect of rotation cause
better nano-particle distribution.
Lakshminarayanan
et al.
2011 Quality weld depends on the weld pitch, i.e. tool
advance per rev. (welding speed / rpm) and can be
increased by increasing the welding speed at constant
rpm or decreasing the rotation speed at constant
welding speed.
Contd.

Scialpi et al. 2007 Used 3 different shoulder geometry (scroll with fillet, cavity with
filet, only fillet)and found that best joint has been welded by
shoulder with fillet.
Zhang et al. 2011 Tool with three spiral flute w/o pin gives better result than inner
concave flute and concentric circle flute.
Forcellese et al. 2012 Used two different tool configuration with different values of
shoulder diameter, both with and w/o pin.
Large shoulder diameter w/o pin gives strong beneficial effect
on both ductility and strength.
Forcellese et al. 2012 Investigated the plastic flow behavior and formability of FSW
AZ31 thin sheet using pin-less tool configuration.
Galvao et al. 2012 Used scrolled and conical shoulder tool. Found that different
geometry had completely different morphology and
intermetallic content using same process parameter.
Galvao et al. 2013 Further researched to see the influence of 3 different geometry
(flat, conical, scrolled) on 1 mm thick copper plate..
RELATED TO SHOULDER GEOMETRY AND PIN
GEOMETRY
MATERIAL FLOW IN FSW
FSW process can be defined as a metal working
process of five conventional metal working zones.
Preheat
Initial deformation
Extrusion
Forging
Post heat / cool down
Contd.
Fig. 6: (a) Metal flow pattern and (b) Metallurgical
processing zones developed during friction
stir welding [54]
WELD MICROSTRUCTURE AND
MECHANICAL PROPERTIES
The microstructure and consequent property
distribution produced during FSW depends on
following factors :
Alloy composition
Alloy temper
Welding parameters
Other geometric factors (Shoulder size, Plate gauge,
etc)
Guerra et al. 2003 Studied the flow of metal using faying surface tracer and a
nib frozen in place during welding. Material is moved
around the nib by two processes both having different
thermo mechanical histories and properties.
Hamilton et al. 2008 Proposed a model of material flow during FSW. They
observed that NZ is the combination of interleaved layers
of particle rich and particle poor material.
Sato et al. 2002 Grain size in the nugget region is determined
predominantly by the peak temperature in the weld. Higher
the peak temperature larger is the grain size.
DISSIMILAR FSW
Cavaleire et al. 2006 Studied the micro and mechanical properties of
dissimilar FSW between 2024 and 7075 Al alloy.
Results showed the fatigue behavior is reduced by
FSW which proves to be an alternative technology
for large part of industrial application.
Somasekharan
et al.
2004 Uneven distribution of micro hardness is observed
in FSW joints between Mg alloy and 6061-T6 alloy
,which is due to complex intercalation structure.
Sato et al. 2004 Found that constitutional liquation is the main
reason for the formation of large volume of
intermetallic compound with higher hardness in
nugget zone.
Yan et al. 2005 Studied the complicated lamellar band formed due FSW
between 1060 Al alloy with AZ31 Mg.
Yong et al. 2010 Studied the dissimilar joining of aluminum to magnesium
with uneven distribution of hardness with higher value
than that of base metal. Further tensile fracture locates at
the AS side where hardness gradient was sharpest.
Dehgani et
al.
2013 Studied the effect of process parameters to control the
amount of intermetallic compound for the production of
sound weld.
Tan et al. 2013 Found excellent bonding between 5A02 Al with pure
copper by lowering one of the process parameter i.e.
traverse speed from 40 mm/min to 20 mm/min.
Li et al. 2012 Studied the dissimilar welding through pin-offset technique of pure
copper to 1350 Al sheet of 3 mm thickness. Complicated
microstructure without intermetallic compound were found in the
nugget zone of welded structure with higher hardness in the
copper side.
Masyuki et
al.
2012 Investigated the effect of pure magnesium and alloying element of
ZK60(Mg-Zn-Zr) on the microstructure of dissimilar joint interface
with titanium.
Bahrami et
al.
2014 Studied the effect of nano-sized particle as well as process
parameter on the friction stir welded aluminum metal matrix
composite.both mechanical and micro structural properties are
enhanced by SiC particle.
Bazmouz
et al.
2011 Fabricated Cu-base Sic reinforced composite. They reported that
grain size is finer with the addition of Sic particles.
Hsu et al. 2005 Fabricted the in-situ composite by friction stir processing which
helps to distribute the Al2Cu particles homogeneously in the
composite.
DEFECTS IN FSW WELDS
Formation of defects are mainly due to improper material
flow or due to geometric factors.
Lack of penetration
Lack of fusion
Surface grooves
Excessive flash
Tunnels
Voids
Kissing bonds
DEFECTS FROM TOO COLD
WELD
Too cold welding condition results in work hardening of
the material.
Causes dry slip between the tool and work piece.
Lack of surface fills/ voids, channel defects are the main
defects due to insufficient heat generation.
The insufficient heat generation causes improper
material mixing and thus responsible for non-bonding.

Kim et al. 2006 Evaluate that at lower rotational speed and high
welding speed insufficient heat input is generated
resulting in cavity/ groove like defects
MULTI-PASS FSW
FSW is capable of producing welds with less defects
but still complete elimination of process upset is not
possible.
Much researchers has been devoted to understand
the effect of process parameters on defect formation
in order to optimize the process parameters for FSW.
Still optimization of process parameters is mostly
done by trial and error.
In the past few decades, there has been research
going on in the field of MP FSW/ FSP where it is
more desirable to repair the defective portion of the
weld than to throw as a scrap.
One of the technique is to repair the defects is
simply
RE-WELDING using nominal process parameter.
MULTI-PASS FSP/FSW
Brown et al. 2009 Significant reduction in feed force when welding is done
over the previous weld. Grain size,hardness,temperature
remains unaffected with passes. Gradual reduction of
residual stress with increasing pass number.
Nataka et al. 2006 Reported an improvement in mechanical properties of Al
die casting alloy of MP FSP compared to as-cast BM.
Ma et al. 2006 No effect of overlapping passes on size, aspect ratio or
distribution of Sic particle while performed five pass with
50% overlap FSP on cast A356.
Leal et al. 2008 Used two different alloy. Quality and strength is not just a
function of parameters but also depend on type of
material and condition of treatment.
Surekha et al. 2008 Investigated that MP FSP showed better corrosion
resistance compared to base metal irrespective of
process parameters.
As FSP is one of the technique for grain
refinement, removing flaws,defects,many
researchers used MP FSP to improve the
properties of as-cast material.
Johannes et al. 2007 Create large area of super plastic materials with properties
using MP FSP. Grain boundary sliding is the most important
mechanism to achieve super plastic deformation.
Ma et al. 2009 Two pass FSP resulted in an enhancement in super plastic
elongation with a optimum rate in the nugget zone of the
second pass and a shift to higher temperature in both central
of second pass as well as transitional zone between passes.
Jana et al. 2010 All single pass runs showed some extent of abnormal grain
growth which was removed with multi-pass.
Higher rotational speed was found to be beneficial for
controlling AGG.
Barmouz et al. 2011 Found that MP FSP reduces the Sic particle size,
improve dispersion and separation of Sic particle by
severe stirring action in the NZ.
Ni et al. 2011 MP overlapping FSP transforms the coarse cast NiAl
bronze alloy (NAB) base metal to get defect free fine
micro structure.
Izadi et al. 2012 Study the effect of MP FSP on distribution and stability
of carbon nano-tube and to fabricate a MMC based on
Al 5059 and MWCNTs.
ADVANTAGES OF CONTRA-ROTATING
FSW TOOLS
New variant technique of FSW/FSP.
Requires less clamping and helps to work with high
welding speed.
Resultant force counters each other so require low
securing force.
Improves the weld integrity by disrupting and fragmenting
the residual oxide layer remaining within the first weld
region by the follower tool.
Weld over the first run produces further break-up and
disposal of oxides with no loss of mechanical properties.
Second tool does not have to robust as the leading tool.
Motion produced is similar to Re-stir ,but twin stir
produces faster travel speeds and in addition, efficiency
of FSW can be further improved with the use of two tools.

OBJECTIVE
To determine the effect of two contra-rotating FSW
tool (Tandem Twin-stir) on the friction stir
processing/welding region on different types of
aluminium alloys.
To study the effect of contra-rotating tool on
mechanical properties and microstructure.
To see the effect of twin tool and single tool with
single as well as two pass and compare the results.
To optimize the process parameters.
EXPERIMENTAL SETUP
Fixture design
Fig. 7: Pictorial view of fixture (a) Fixture installed over
milling machine bed (b) Welding plates clamped over
fixture
EXPERIMENTAL
SETUP
Fig. 8: Pictorial view of twin tool attachment
(a) Old one (b) New one
(c)

(d)

Fig.8(e) Inner assembly and (f) Inner isometric view
WORK MATERIAL
Work piece material commercially pure aluminium alloy
Work piece size 200 mm x 80 mm x 2.5 mm
Chemical composition (weight %) of work piece material
Si Fe Cu Mn Mg Zn Ti Ga Na Others, each
Remainder
Aluminium
0.7055 0.831 0.00505 0.013 0.00465 0.0031 0.0048 0.0118 0.00245 Max. 0.05% 98.7
Mechanical properties of base metal
Yield Strength in MPa Ultimate strength in MPa Elongation in % age
Hardness at 200 gmf load in
VHN
106.47 119.79 16.39 35-46 HV
TOOL MATERIAL
Tool material SS316
Shoulder diameter 16 mm
Pin diameter 5 mm
Pin length 2 mm
D/d ratio of tool 3.2
Chemical composition (weight %) of Tool
Material SS316
Si P Mn Cr Ni Mo Fe
2.13 0.27 8.95 16.29 0.2 0.14 72.01
Fig. 9: FSP/FSW tool
dimensions
PROCESS PARAMETERS
No of tools 2
Rotational speed 4
Welding speed - 3
Total experiments - 36
Process parameters Values
Rotational speed (rpm) 900, 1120,1400,1800
Welding speed (mm/min) 16,31.5,63
D/d ratio of tool 3.2
Pin length (mm) 2
Tool shoulder, D (mm) 16
Pin diameter (mm) 5
Tensile test specimen

Fig. 13: Dimension of the tensile test specimen
RESULTS AND DISCUSSION
Following weld joints properties were studied:
Macrostructure analysis of welded samples
Micro-hardness
Ultimate tensile strength
Yield strength
% elongation
Joint efficiency
Macro and microscopic Study of fractured tensile test
pieces using optical microscope and SEM
RESULTS AND
DISCUSSION
Sl.
No
Sample
parameter
TT ST-SP ST-DP
1
900-16
2
1120-16
3
1400-16
4
1800-16
Tunnel at middle
Tunnel with
pinhole
Pin hole at
middle
Tunnel at upper
side
Table 6.1: Effect of TT, ST-SP, and ST-DP on macrostructure of the FSW zones
Sl.
No
Sample
parameter
Twin Tool Single Pass Multi Pass
5
900-31.5
6
1120-31.5
7
1400-31.5
8
1800-31.5

Elongated tunnel at
middle
Small tunnel at
middle
Tunnel at
bottom
Tunnel
defect
Worm hole at
center
Contd
.
Sl.
No
Sample
parameter
Twin Tool Single Pass Multi Pass
5
900-63
6
1120-63
7
1400-63
8
1800-63

Defect free pinhole at bottom
Pinhole at
bottom
Defect free
Tunnel at middle
Defect free
Contd
.
Defect free
Defect free
Average micro hardness of 12 welded samples and
base metal using TT, ST-SP, ST-DP
Sample No. TT ST-SP ST-DP
BM 42.68 - -
900-16 32.18 31.73 33.18
1120-16 32.67 35.00 33.25
1400-16 33.38 34.44 35.08
1800-16 38.87 34.62 35.12
900-31.5 34.10 37.86 34.42
1120-31.5 33.14 31.39 34.13
1400-31.5 34.86 31.83 33.12
1800-31.5 33.73 33.19 31.67
900-63 31.48 33.18 33.77
1120-63 34.68 33.58 36.15
1400-63 33.41 36.42 32.91
1800-63
39.42
35.23 35.32
MICRO HARDNESS
Contd.
Fig. 15: Average micro hardness of 12 samples and
base metal using TT,ST-SP, ST-DP
1 2 3 4 5 6 7 8 9 10 11 12
0.0
2.5
5.0
7.5
10.0
12.5
15.0
17.5
20.0
22.5
25.0
27.5
30.0
32.5
35.0
37.5
40.0
42.5
45.0
A
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H
V
Sample Parameter
TT
ST-SP
ST-DP Base Metal
Effect of TT, ST-SP, and ST-DP on the nugget zone
hardness
1
-12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12
20
22
24
26
28
30
32
34
36
38
40
H
a
r
d
n
e
s
s

(
H
V
)
Distance from weld centre (mm)
900-16(TT)
900-16(ST-SP)
900-16(MP)
2
-10 -8 -6 -4 -2 0 2 4 6 8 10
20
22
24
26
28
30
32
34
36
38
40
1120-16(TT)
1120-16(ST-SP)
H
a
r
d
n
e
s
s

(
H
V
)
1120-16(ST-DP)
3
-10 -8 -6 -4 -2 0 2 4 6 8 10
20
22
24
26
28
30
32
34
36
38
40
42
1400-16(TT)
1400-16 (ST-DP)
H
a
r
d
n
e
s
s

(
H
V
)
1400-16(ST-SP)
4
-10 -8 -6 -4 -2 0 2 4 6 8 10
20
25
30
35
40
45
50
1800-16(TT)
1800-16(ST-SP)
1800-16(ST-DP)
Contd.
9
-10 -8 -6 -4 -2 0 2 4 6 8 10
28
30
32
34
36
38
40
42
44
46
900-31.5(TT)
900-31.5(ST-SP)
H
a
r
d
n
e
s
s

(
H
V
)
900-31.5(ST-DP))
10
-10 -8 -6 -4 -2 0 2 4 6 8 10
5
10
15
20
25
30
35
40
45
1120-31.5(TT)
1120-31.5(ST-SP)
H
a
r
d
n
e
s
s

(
H
V
)
1120-31.5(ST-DP)
11
-10 -8 -6 -4 -2 0 2 4 6 8 10
20
22
24
26
28
30
32
34
36
38
40
1400-31.5(TT)
1400-31.5(ST-SP)
H
a
r
d
n
e
s
s

(
H
V
)
1400-31.5(ST-DP)
12
-10 -8 -6 -4 -2 0 2 4 6 8 10
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
H
a
r
d
n
e
s
s

(
H
V
)
1800-31.5(TT)
1800-31.5(ST-SP)
1800-31.5(ST-DP)
Contd.
5
24
26
28
30
32
34
36
38
-10 -8 -6 -4 -2 0 2 4 6 8 10
H
a
r
d
n
e
s
s

(
H
V
)
900-63(TT)
900-63(ST-SP)
900-63(ST-DP)
6
-8 -6 -4 -2 0 2 4 6 8 10
20
22
24
26
28
30
32
34
36
38
40
1120-63(TT)
H
a
r
d
n
e
s
s

(
H
V
)
1120-63(ST-SP)
1120-63(ST-DP)
7
-10 -8 -6 -4 -2 0 2 4 6 8 10
20
22
24
26
28
30
32
34
36
38
40
1400-63(TT)
1400-63(ST-SP)
1400-63(ST-DP)
H
a
r
d
n
e
s
s

(
H
V
)
8
-10 -8 -6 -4 -2 0 2 4 6 8 10
25
30
35
40
45
50
1800-63(TT)
H
a
r
d
n
e
s
s

(
H
V
)
1800-63(ST-SP)
1800-63(ST-DP)
Effect of rotational speed on average micro-hardness
of FSW zone using TT, ST-SP, and ST-DP
Fig.17 (a-c)
900-16 1120-16 1400-16 1800-16
31
32
33
34
35
36
37
38
39
At constant welding speed= 16 mm/ min
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Sample Parameter
TT
ST-SP
ST-DP
900-31.5 1120-31.5 1400-31.5 1800-31.5
30
32
34
36
38
40
42
At constant welding speed= 31.5 mm/ min
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Sample Parameter
TT
ST-SP
ST-DP
900-63 1120-63 1400-63 1800-63
30
32
34
36
38
40
At constant welding speed= 63 mm/ min
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Sample Parameter
TT
ST-SP
ST-DP
Effect of welding speed on average micro hardness
of FSW zone using TT, ST-SP, and ST-DP
Fig.18(a-d)
900-16 900-31.5 900-63
30
32
34
36
38
40
42
At constant rotational speed= 900 rpm
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Sample Parameter
TT
STSP
ST-DP
1120-16 1120-31.5 1120-63
31.0
31.5
32.0
32.5
33.0
33.5
34.0
34.5
35.0
35.5
36.0
36.5
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Sample Parameter
TT
ST-SP
ST-DP
1400-16 1400-31.5 1400-63
31
32
33
34
35
36
37
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Sample parameter
TT
ST-SP
ST-DP
1800-16 1800-31.5 1800-63
31
32
33
34
35
36
37
38
39
40 At constant rotational speed= 1800 rpm
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Sample Parameter
TT
ST-SP
ST-DP
Tensile test data of FSW samples using TT, ST-
SP, ST-DP
Sample
parameter
YIELD STRENGTH UTS % ELNG JOINT EFF.
TT ST-SP ST-DP TT ST-SP ST-DP TT ST-SP ST-DP TT ST-SP ST-DP
BM 106.4
7
106.4
7
106.47 119.79 119.79 119.79 14.22 14.22 14.22 100 100 100
900-16 42.01 34.78 43.04 85.82 38.04 59.45 20.67 2.49 5.2 71.64 31.75 49.6
1120-16 40.56 36.38 38.67 84.23 88.95 85.71 20.45 26.51 24.44 70.31 74.25 71.6
1400-16 36.79 35.17 43.47 59.74 85.76 86.46 6.86 22.42 20.52 49.87 71.59 72.2
1800-16 36.54 34.82 40.3 86.59 86.92 85.5 23.9 26.91 20.19 72.28 72.56 71.4
900-31.5 44.2 44.07 43.78 87.09 64.65 86.87 19.41 10.12 21.57 72.7 53.97 72.5
1120-31.5 42.76 23.94 45.56 67.95 25 85.84 5.95 2.14 20.22 56.72 20.87 71.7
1400-31.5 38.03 40.35 39.23 85.91 86.02 88.03 22.79 28.01 22.29 71.72 71.81 73.5
1800-31.5 36.06 40.53 37.97 85.25 88.54 86.16 23.1 26.66 24.08 71.17 73.91 71.9
900-63 39.03 38.4 45.4 85.12 69.91 80.19 20.39 9.66 13.35 71.06 58.36 66.9
1120-63 38.46 39.49 39 80.06 86.31 85 14.75 20.45 20.93 66.83 72.05 71
1400-63 40.64 38.57 44.81 86.56 87.08 87.19 23.26 22.69 20.17 72.26 72.69 72.8
1800-63 38.82 37.04 39.49 84.6 85.62 86.78 21.02 24.51 19.62 70.62 71.48 72.4
Effect of TT, ST-SP, and ST-DP on YS, UTS, % age
of elongation and joint efficiency of the welded
samples
1
YS UTS %ELNG JOINT EFF.
0
20
40
60
80
Sample Parameter
900-16(TT)
900-16(ST-SP)
900-16(ST-DP)
Y
S
,

U
T
S

i n

M
P
a
%

o
f

E
l n
g
,

J
o
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t

E
f
f
.

i n

p
e
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c
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n
t
a
g
e
2
0
20
40
60
80
Sample Parameter
1120-16(TT)
1120-16(ST-SP)
1120-16(ST-DP)
%

o
f

E
l n
g
,

J
o
i n
t

E
f
f
.

i n

p
e
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Y
S
,

U
T
S

i n

M
P
a
3
0
10
20
30
40
50
60
70
80
90
Sample Parameter
1400-16(TT)
1400-16(ST-SP)
1400-16(ST-DP)
Y
S
,

U
T
S

i n

M
P
a
%

o
f

E
l n
g
,

J
o
i n
t

E
f
f
.

i n

p
e
r
c
e
n
t
a
g
e
4
0
20
40
60
80
Sample Parameter
1800-16(TT)
1800-16(ST-SP)
1800-16(ST-DP)
%

o
f

E
l
n
g
,

J
o
i
n
t

E
f
f
.

i
n

p
e
r
c
e
n
t
a
g
e
Y
S
,

U
T
S

i
n

M
P
a
0
20
40
60
80
Y
S
,
U
T
S

i
n

M
P
a
Sample Parameter
900-31.5(TT)
900-31.5(ST-SP)
900-31.5(ST-DP)
%
o
f

E
l
n
g
,
J
o
i
n
t

E
f
f
.

i
n

p
e
r
c
e
n
t
a
g
e
0
10
20
30
40
50
60
70
80
90
Y
S
,
U
T
S

i
n

M
P
a
Sample Parameter
1120-31.5(TT)
1120-31.5(ST-SP)
1120-31.5(ST-DP)
%

o
f

E
l
n
g
,
J
o
i
n
t

E
f
f
.
i
n

p
e
r
c
e
n
t
a
g
e
6
0
20
40
60
80
Sample Parameter
1400-31.5(TT)
1400-31.5(ST-SP)
1400-31.5(ST-DP)
%

o
f

E
l
n
g
,

J
o
i
n
t

E
f
f
.

i
n

p
e
r
c
e
n
t
a
g
e
Y
S
,

U
T
S

i
n

M
P
a
7
0
20
40
60
80
%

o
f

E
l
n
g
,

J
o
i
n
t

E
f
f
.

i
n

p
e
r
c
e
n
t
a
g
e
Y
S
,

U
T
S

i
n

M
P
a
Sample Parameter
1800-31.5(TT)
1800-31.5(ST-SP)
1800-31.5(ST-DP)
10
0
20
40
60
80
Sample Parameter
900-63(TT)
900-63(ST-SP)
900-63(ST-DP
%

o
f

E
l
n
g
,

J
o
i
n
t

E
f
f
.

i
n

p
e
r
c
e
n
t
a
g
e
Y
S
,

U
T
S

i
n

M
P
a
11
0
20
40
60
80
Sample Parameter
1120-63(TT)
1120-63(ST-SP)
1120-63(ST-DP)
%

o
f

E
l n
g
,

J
o
i n
t

E
f
f
.

i n

p
e
r
c
e
n
t
a
g
e
Y
S
,

U
T
S

i n

M
P
a
12
0
20
40
60
80
%

o
f

E
l
n
g
,

J
o
i
n
t

E
f
f
.

i
n

p
e
r
c
e
n
t
a
g
e
Sample Parameter
1400-63(TT)
1400-63(ST-SP)
1400-63(ST-DP)
Y
S
,

U
T
S

i
n

M
P
a
9
0
20
40
60
80
Sample Parameter
1800-63(TT)
1800-63(ST-SP)
1800-63(ST-DP)
%

o
f

E
l n
g
,

J
o
i n
t

E
f
f
.

i n

p
e
r
c
e
n
t
a
g
e
Y
S
,

U
T
S

i n

M
P
a
Contd.
Effect of welding speed on yield strength of welded
joints using TT, ST-SP and ST-DP.
900-16 900-31.5 900-63
34
36
38
40
42
44
46
Rotational speed=900 rpm(const.)
Y
S

i
n

M
P
a
Sample parameter
TT
ST-SP
ST-DP
1120-16 1120-31.5 1120-63
25
30
35
40
45
Y
S

i
n

M
P
a
Sample parameter
TT
ST-SP
ST-DP
1400-16 1400-31.5 1400-63
34
36
38
40
42
44
46
Y
S

i
n

M
P
a
Sample parameter
TT
ST-SP
ST-DP
1800-16 1800-31.5 1800-63
36
38
40
Y
S

i
n

M
P
a
)
Sample parameter
TT
ST-SP
ST-DP
Effect of welding speed on ultimate tensile strength of
welded joints using twin tool, single pass and two
pass
900-16 900-31.5 900-63
40
50
60
70
80
90
Rotational speed=900 rpm (const.)
U
T
S

i
n

M
P
a
Sample parameter
TT
ST-SP
ST-DP
1120-16 1120-31.5 1120-63
20
30
40
50
60
70
80
90
U
T
S

i
n

M
P
a
Sample parameter
TT
ST-SP
ST-DP
1400-16 1400-31.5 1400-63
60
65
70
75
80
85
90
U
T
S

i
n

M
P
a
Sample parameter
TT
ST-SP
ST-DP
1800-16 1800-31.5 1800-63
85
86
87
88
89
U
T
S

i
n

M
P
a
Sample parameter
TT
ST-SP
ST-DP
Effect of welding speed on %age of elongation of
welded joints using TT, ST-SP, and ST-DP
900-16 900-31.5 900-63
5
10
15
20
%

o
f

E
l
o
n
g
a
t
i
o
n
Sample parameter
TT
ST-SP
ST-DP
1120-16 1120-31.5 1120-63
0
5
10
15
20
25
%

o
f

E
l
o
n
g
a
t
i
o
n
Sample parameter
TT
ST-SP
ST-DP
1400-16 1400-31.5 1400-63
5
10
15
20
25
%

O
F

E
l
o
n
g
a
t
i
o
n
Sample parameter
TT
ST-SP
ST-DP
1800-16 1800-31.5 1800-63
20
22
24
26
%

o
f

E
l
o
n
g
a
t
i
o
n
Sample parameter
TT
ST-SP
SP-DP
Effect of welding speed on joint efficiency of welded
joints using TT, ST-SP, and ST-DP
900-16 900-31.5 900-63
30
40
50
60
70
Rotational speed= 900 rpm (const.)
J
o
i
n
t

e
f
f
i
c
i
e
n
c
y

i
n

%

a
g
e
Sample parameter
TT
ST-SP
ST-DP
1120-16 1120-31.5 1120-63
20
30
40
50
60
70
80
J
o
i
n
t

e
f
f
i
c
i
e
n
c
y

i
n

%

a
g
e
Sample parameter
TT
ST-SP
ST-DP
1400-16 1400-31.5 1400-63
50
55
60
65
70
75
J
o
i
n
t

e
f
f
i
c
i
e
n
c
y

i
n

%

a
g
e
Sample parameter
TT
ST-SP
ST-DP
1800-16 1800-31.5 1800-63
70.5
71.0
71.5
72.0
72.5
73.0
73.5
74.0
J
o
i
n
t

e
f
f
i
c
i
e
n
c
y

i
n

%

a
g
e
Sample parameter
TT
ST-SP
ST-DP
Appearance of the test pieces after tensile
tests
TT ST-SP ST-DP
900-16
1120-16
1400-16
1800-16
900-31.5
1120-
Contd
.
TT ST-SP ST-DP
1400-
31.5
1800-
31.5
900-63
1120-
63
1400-
63
1800-
63
Appearance of the test pieces after tensile
tests
Macrographs of fractured tensile samples
T T ST-SP ST-DP
BM
900-16
1120-
1400-
1800-
Contd.
TT ST-SP ST-DP
900-31.5
1120-
31.5
1400-
31.5
1800-
31.5
Contd.
TT ST-SP ST-DP
900-63
1120-63
1400-63
1800-63
SEM image of the fractured surface
TT ST-SP ST-DP
BM
900-16
Ductile failure
with high
elongation
Ductile failure With
low elongation
Quasi cleavage type
Partly Ductile and
partly brittle fracture
1400-16
1800-
31.5
Combination of ductile
and cleavage type
fracture
Ductile fracture Ductile fracture
Contd.
Contd.
TT ST-SP ST-DP
1800-
31.5

1400-
63
Ductile fracture
Ductile fracture
Ductile fracture Completely brittle
fracture
Conclusions

In this investigation an attempt has been made to study the effect of twin
tool and single pass and two pass with single tool on the formation of
friction stir welding zone in a commercially pure aluminium alloy with
different rotational speed and welding speed. From this, the following
important conclusions are derived:
The entire joints fabricated using twin tool at higher rpm and high welding
speed are found to be free from defects. From the macrostructure
analysis it can be inferred that formation of defect free FSW zone is a
function of both rotational speed and welding speed used.
Welds made with twin tool shows some higher value of hardness
compared to the single pass and two pass in FSW joints for most of the
welding parameters. It is revealed that the maximum hardness value of
39.42 HV is recorded corresponding to 1800 rpm with 63 mm/min
welding speed using twin tool.
For 900 rpm and 31.5 mm/min welding speed, twin tool exhibit better YS,
UTS as compared to single pass and two pass welded samples.
It is observed that 31.5 mm/min welding speed is the critical point where
there is a sudden change in the mechanical strength for all the cases.
This similar scenario is observed in case of ultimate strength, percentage
of elongation and joint efficiency also.
Future work
The following studies are required for future work-
Studies have to be focused on different types of FSW tool
designs which increases the tool travel speed, swept volume
and also increase the weld symmetry of the joints.
Further different types of shoulder and tool designs to be used
to find out the optimum design for the twin tool experiment.
Both power consumption and temperature measurement during
welding operation have to be analysed using power sensor and
thermography method.
Different optimization techniques has to be incorporated to
select the appropriate combination of process parameter viz.
Speed, feed rate and see the effect of tool tilt angle in twin tool
set up.
After finding out the optimum parameter studies have to be
focused at the optimum parametric combination to analyse what
is the scenario in twin tool and single tool with single as well as
two pass.
Studies has to be done using four component rotating type
dynamometer with twin tool attachment to see the effect of
counter rotating tool on the generation of torque during welding.

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Contd
.
THANK YOU

Friction Stir Welding ENHANCEMENT SEMINAR Friction Stir Welding

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CONTENTS

Introduction to Friction Stir Welding and Processing

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